Welding is the unquestioned method for permanently joining materials because it bonds them at the molecular level. That deep! Metal machining industries just cannot function without welding.

Wind-Power, automotive, and building-construction will continue to create demand for the welding equipment market. Transparency Research Market expects the global welding equipment market to grow to $23.78billion by 2020. Global Research and Data Services forecasts the growth of this market at 4% p.a. in 2014-18.

Arc Welding makes up 40% of the global welding-product market on account of its simplicity, versatility, flexibility, and cost-effectiveness. It is indispensable for building ships, power plants, automobiles, and steel-frame buildings. As a fabricator, you just cannot do without knowing best arc welding practices.

For Top-Class Stick Welding

Although Shielded Metal Arc Welding (SMAW) welding is the most tolerant to dirt and rust, don’t take this for granted for unclean materials can cause porosity, cracks, inclusions, and fusions.

Select a comfortable position from where you can maneuver the electrode while having a full view of the puddle. Keeping your head at the side, away from smoke provides an excellent view. Warm up the rod on scrap material before you start.

CLAMS or current setting, length of arc, angle of electrode, manipulation of electrode, and speed of travel are the five techniques for best stick welding:

Current Setting: the electrode/rod determines the current setting: AC, DC-negative, or DC-positive. The type and diameter of electrode and the welding position determine the amperage

Most SMAW procedures need machines of 200amperes or less. For material over 3/8-inch thick, employ multiple passes with the same machine. Select current levels that generate 15% less heat for overhead welds vis-à-vis flat welds

Effect of Current on Weld Quality (Source: http://www.mig-welding.co.uk/arc-welding-faults.htm)

High currents make the arc louder, char the electrode rapidly, and produce extremely fluid puddles. Low amperages extinguish and stutter the arc and sticl the rod to the workpiece

You don’t need weaving for material of or under ¼-inch thickness. Restrict the weaving width to 2.5 times the electrode-core diameter. Undertake multiple weaving passes for thicker joints

Weaving for overhead welds is the toughest. Keep the electrode inside the molten puddle while weaving. Outside the puddle, electrical resistance decreases suddenly creating a current surge that showers sparks and gives out a loud pop

For vertical-upward welding, slowly move the electrode from the middle to the side and pause momentarily at the sides. This prevents the puddle from lagging the rod, ensures strong bonding with the sides, and prevents undercut edges

For positions other than vertical-upwards, weave fast when at the center of the puddle to prevent high crowns i.e. central bulges. Common weave types:

triangular weaves efficiently fill steep pockets

semi-circular weaves with the stroke crossing the front of the puddle prevent puddle overheating

pulling crescent or semi-circular weaves back through the puddle generates greater heat

Speed of Travel: must maintain the arc in the leading one-third part of the pool but not exceed the rate at which the arc melts the base metal

Stickout or Electrode Extension is the distance between the arc and the contact tube measured along the length of the wire. Smaller stickout boosts weld heat and penetration while checking heat-buildup in the electrode.